A New Era for Distributed Control Systems (DCS)
ABB has launched Automation Extended, a forward-looking evolution of its distributed control system (DCS) architecture. This program enables industries to modernize control systems without operational downtime, bridging traditional automation reliability with emerging digital innovations such as AI, IoT, and edge computing.
In an era where industrial plants face volatile market conditions, cybersecurity challenges, and skill shortages, ABB’s initiative addresses the need for agile yet stable automation platforms that protect existing investments while accelerating digital transformation.
Building on ABB’s Proven Automation Legacy
With the world’s largest installed base of DCS, ABB leverages decades of process automation expertise. The Automation Extended strategy enhances trusted systems like ABB Ability™ System 800xA®, ABB Ability™ Symphony® Plus, and ABB Freelance, ensuring that customers can integrate new capabilities gradually and securely.
This evolutionary approach provides a low-risk pathway to modernization, allowing operators to sustain production while introducing AI-driven analytics, IoT connectivity, and modular software enhancements.
According to Peter Terwiesch, President of ABB’s Automation business, “Industrial modernization must prioritize continuity. Automation Extended empowers customers to adopt innovation at their own pace—without compromising reliability or security.”
Open and Modular Architecture for Future-Ready Operations
At the heart of ABB’s Automation Extended lies a separation-of-concerns architecture, a design principle that distinctly isolates the control domain from the digital domain.
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The Control Environment delivers deterministic, secure, and real-time process control, ensuring system stability and regulatory compliance.
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The Digital Environment connects securely to the control layer, enabling AI-based analytics, predictive maintenance, and edge intelligence—all without affecting mission-critical processes.
This dual-layer ecosystem provides scalability and modularity, allowing industries to adopt next-generation technologies incrementally while maintaining full operational integrity.
Integrating AI, Cloud, and IoT for Smarter Plants
The new automation ecosystem integrates technologies such as Open Platform Communications Unified Architecture (OPC UA) and Cloud-Native Architecture, featuring containerization and service orchestration.
These capabilities enable advanced functions like condition monitoring, process anomaly detection, and modular engineering deployment across diverse hardware platforms.
As a result, industrial operators can enhance performance visibility, reduce unplanned downtime, and optimize lifecycle costs through real-time insights and proactive decision-making.
Simplified Lifecycle Management Across the Ecosystem
ABB’s unified service model offers comprehensive lifecycle management for both traditional and digital automation components. This approach streamlines system maintenance, upgrades, and cybersecurity oversight, ensuring consistent performance across complex industrial assets.
Moreover, by centralizing support under a single automation service framework, ABB simplifies vendor coordination and strengthens system reliability for multi-site industrial operations.
Industry Perspective: Why This Matters for the Future of Automation
The Automation Extended initiative reflects a broader industry shift toward hybrid automation environments, where legacy reliability meets cloud-driven flexibility.
As factories evolve into data-centric operations, interoperability and modularity become crucial differentiators. ABB’s approach aligns with global trends toward open automation standards, ensuring future compatibility with both industrial and digital ecosystems.
From an industry analyst’s perspective, this program demonstrates ABB’s strategic vision—protecting customer investments while preparing them for autonomous and AI-enhanced operations. It represents not just a technical upgrade, but a philosophical transition in industrial automation design.
Application Scenarios and Solutions
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Process Industries: Continuous process plants can integrate advanced analytics without disrupting control logic, enhancing energy efficiency and throughput.
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Manufacturing: Modular upgrades allow flexible production adjustments using digital twins and AI-based process optimization.
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Utilities: Remote monitoring and predictive asset management improve reliability in power generation and water treatment facilities.
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Oil & Gas: Securely bridging field devices with enterprise data systems enables real-time performance insights across distributed assets.